Pile fabric and machine for making the same



Dec.`14, 1937. E. HoPKlNsoN PILE FABRIC AND MACHINE FOR MAKING- THE SAME 5 Sheets-Sheet l Original Filed Nov. 2, 1929 Dec. 14, 1937. E. HoPKlNsoN 2,101,906

PILE FABRIC AND MACHINE FOR MAKING THE SAME Original Filed NOV. 2, `1929 5 Sheets-Sheet 2 Dec. 14, 1937.

E. HOPKINSON PILE FABRIC AND MACHINE FOR MAKING THE SAME originl Filed Nov. 2, 1929 5 sheets-sheet :s

BY v. ATTORI/56K Dec. 14, 1937. E. HOPK|N$ON 2,101,906

PILE FABRIC AND MACHINE FOR MAKING THE SAME Original Filed Nov. 2, 1929 5 Sheets-Sheet 4 A TTORNEY Dec. 14, 1937. E.`HoPK|NsoN 2,101,906

I PILE FABRIC AND MACHINE FOR MAKING THE SAME Original Filed Nov. 2, 1929 5 Sheets-,Sheet 5 A TTORIMEY Patented Dec. 14, 1937 2,101,006 Pnnrannrcannmcmns mamma.

m sans Ernest Hopkimon, New York, N. Y., asaignor, by

meme assignments, to United States Rubber. company, New York, N. Y., a corporation of New Jerney 404,457.. Divided n November 2, 1929. Serial No.

and this 1931, Serial No. 549.886

application July 9,

11 cui. (ci. 154-1) This invention relates to pile fabrics, to a process for manufacturing pile fabrics and `to a machine for manufacturing pile fabrics in accordance with that process.

This application is a division of my co-pending application Serial No. 404,457, filed November 2,

Heretofore in the manufacture of pile fabrics it has been usual to weave the pile into a backing of woven fabric, the fabric serving to secure the pile in place. The free ends of the pile have heretofore been formed by cutting off the top portions of the loops formed by weaving the yarn into the fabric. Such an Iarticle is unduly expensive because of the type of backing. The process of making such an article is unnecessarily complicated by the type of backing employed and is rendered costly because of the operations necessary in securing the pile .into the fabric. That process is further wasteful, in that, in vcutting off the top portions of the loops to form the free ends of the pile, a considerable amount of bre is wasted. In addition machines capable of making pile fabric with a fabric backing are necessarily complicated in order that they may carry out the operations Vof weaving the pile into the fabric backing.

It is an object of this invention to provide a pile fabric in which the fibres forming the pile are secured solely by an adhesive. Another object of this invention is to provide a pile fabric having a high degree of iiexibility. It is also an objectI of this invention to provide a process for making a pile fabric in which the pile is secured together solely by adhesive. It is `a further object of this invention to provide a process for making two pile fabrics at one operation. Another object of this invention is to provide a process whereby the loops in the folds of fibrous material making up the pile are secured together a* both faces of the folds, and furtherto separate such sheet between the faces formed by the loops of the fold. It is also an object of this invention to provide a machine for manufacturing the pile fabric herein described according tothe process herein described.

Other objects and advantages of the present invention will appear from the following detailed description taken in connection with the accompanying drawings, in which:

Fig. 1 is an end elevation partly broken away with parts in section of the pile fabric machine of this invention;

Fig. 2 is a top plan view of the -pile fabric ma- Fig. 3 is a side elevation partly broken away of the pile fabric machine of 'this invention;

Fig. 4 is a diagrammatic view of.` the entire machine:

- Fig. 5 is a detail view partly in section of the web folding mechanism of the pile fabric machine;

Fig. 6 is a detail view of the adhesive applying apparatus;

Fig. 7 is a detail view of the cutting apparatus:

Figs. 8, 9, 10, 11 and 12 are views of the products:

Fig. 13 is a view partly broken away and in section of a modification of the machine of this invention.

According to theprocess of this invention, a web of fibrous material is continuously advanced. The web may be composed of a plurality of strands placed side by side in parallel relation or the web may be composed of a matted or, f elted material or' it may be a sheet of paper, or any other material having the strength and flexibility necessary for folding. 'Ihe fibrous material may be either vegetable or animal fibres such as cotton, jute. hemp, sisal, ax, wool, hair, and in addition artiiicial bres such as artificial silk.

The mechanism for continuously supplying .the web may conveniently take the form, in the case of a plurality of juxtaposed strands, of a beam I or in lieu thereof a reel from which the strands individually may be drawn. The web is drawn from the source of supply by rollers 2 driven from any suitable source of power, not shown. The web W passes through the rollers 2 which contact therewith and by friction draw the web from a source of supply and advance the web continuously to the folding mechanism. A roller 3 is conveniently provided for properly aligning the web with the rollers 2. Where the web is composed of a plurality of strands in side to side parallel relation, an expansion comb 4 of conventional construction is provided for maintaining the strands in proper alignment and properly spaced. A frame 5 of suitable construction is provided for carrying the parts described as shown in Fig. 1, the various rollers in the beam being rotatably mounted in the frame and the. comb fixed thereto in any well known manner. v

The next step in the process consists in fornilng folds in the web as it advances continuously. The folds are formed in succession and the folds are arranged in contiguous relation and are of equal depth.

The mechanism for forming the folds in the web W conveniently takes the form of plates or blades 8 and 1 which are mounted in parallel relation and for reciprocating movement parallel to one another, that is reciprocating move-I ment in a plane` perpendicular to the direction of movement of the web. Inz addition as will be later described the blades are mounted for reciprocating movement in a direction parallel to the direction of movement of the web. In mak ing the folds in the web, the blades 8 and 1 operate in the following fashion: As shown most clearly in Figs. 1, 5 and 13 the blade 8 Isin extended position. In that position the edge oi' the blade 8 holds the web against the face of a casting 8 which extends across the entire width of the web. The blade 8 holds the web W thereby preventing the withdrawal of the previously formed loops while the blade 1 moves from the position shown in Fig. 1 to the left, thus forming a fold in the web W. When the b1ade`1 reaches its fully extended position its edge clamps the web against the face of the casting 8. The castings 8 and 8 carry cap plates 48 and 41 respectively later to be described which cooperate with the blades 8 and 1 in the formation of the folds therebetween. As soon as the blade 1 effectually secures the web W against the face of the casting 8, the blade 8 iswithdrawn, leaving the formed loops between the faces of the castings 8 and 8.1 When the blade 8i has been fully withdrawn the castings 8 and 8 then move parallel to the direction of movement of the web W. The casting 8 moves upwardly and the casting 8 -moves downwardly. Inasmuch as at this time the blade 8 is fully withdrawn, it clears the last formed fold in the web, and inasmuch as the blade 1 is fully extended and holds the web against the face of the casting 8. it carries the last formed fold in the web downwardly in the slot I8 between the faces of the castings 8 and 8. When thev castings 8 and 8 have reached the full extent of their movement, they then stop and the blades 8 and 1 are in a position which is reverse to that shown in Fig. 1. At that time the blade 8` moves outwardly to the right until it ,reaches its fully extended position, in which position its edge holds the web against the face of the casting 8. Then the blade 1 is withdrawn, the castings 8 and 8 move in a direction parallel to the direction of motion of the web, but in the reverse of the. last described movement of the castings 8 and 8 to bring the blades and castings to their original position as shown in Fig. l. This operation has involved the formation of two folds in the web W.

The construction of the machine whereby the castings 8 and 8 operate in a direction parallel to the direction of movement of the web W will now be described. The castings 8 and 8 extend from end to end of the machine and at their lateral extremities the castings 8y and 8 carry sleeves II and I2 respectively, which sleeves are rigidly secured thereto or are unitary therewith. The sleeves III and I2 fit and slide upon posts I8 and I4 respectivelyv which are rigid with castings I8 secured to the base of the machine I8 by bolts I8. Brackets I1 and I8 are carried by the castings 8 and 8 respectively and extend between the sleeves II at each end of the castings 8 and between the sleeves I2 at each end of the casting 8 respectively. The brackets I1 and I8 are recessed as indicated at I8 and 28 (Fig. 2) and blocks 2i and 22 are secured on the brackets I1 and I8 respectively and bridge over the recesses I8 and 28 so as to form a slot between the bottom of the recesses I8 and 28 and the faces of the blocks 2i and 22 respectively. Isnks 28 and 24 extend into the last described slots in the brackets I1 and I8 respectively. The links 28 and 24 are rotatably secured to the castings 8 and 8 by the pins 28 and 28.1l The links 28 and 24'c'onnect at their other extremities with radius arms 21 and yV28 rigidly fixed to shafts 28 andY 88 rotatably mounted in brackets 8l and 82 rigidly carried in any suitable manner on the frame of the machine. The shafts'28 and 88 extend from end to end of the machine as shown in Fig. 2, the links 28 and 24 being connected to the radius arms 21 and 28 at the ends of the shafts 28 and 88 respectively. Intermediate of the extremities of the shafts 28 and 88, cam levers 88 and 84 are carried rigidly fixed to the shafts 28 and 88 respectively. The cam levers 88 and 84 carry cam followers 88 and 88 respectively which ride in slots- 81 and 88 of cams 88 and 48 respectively. The cams 88 and 48 are rigidly secured upon the shafts 4I and 42 respectively which are rotatably supported in suitable bearings carried on the frame I8 of the machine. At the extremities of the shafts 4I and 42 are nxed bevel gears 48 andy 44 which mesh with bevel gears carriedon theA extremities of the shaft 48 uponwhichis rigidly fixed .a sprocket 48. Power is supplied from any suitable source through the :sprocket 48 and shaft, 48 to the shafts 4 I yand 42 and thereby to the' cams 88 and 48 so as to effect the operation of the castings 8 and 8 through the motion transmitting mechanism hereinabove described. As the cams 88 and 48 rotate the oscillations' of the cam levers 88 and 84 cause the links 28 and 24 fto move vertically as shown in Fig. l thereby mov-y ing the castings 8 and 8 vertically uponthe pins I8 and I4. The cam slots 81 and 88 yare -so designed as to cause the castings 8 and 8 to move in opposite directions when moving and simultaneously to remain stationary.

The mechanism for effecting the reciprocatin of the blades 8 and 1 in a plare perpendicular to the direction of movement of the web W will now be described. The blades 8 and 1 slide upon top faces of the castings 8 and 8 and are held in sliding relation therewith by cap plates 41 and 48 respectively.

The cap plates 41 and 48 are secured to the castings 8 and 8 respectively by screws 48 arranged-at intervals along the cap plates 41 and 48. Washers 88 of a slightly greater 4thickness I than the blades 8 and 1 are positioned between the cap plates and castings in order properly-to space them so as to permit free sliding movement of the blades 8 and 1^therebetween..1'l'he, plates or blades 8 and 1 are provldedwith 'slots 8I adapted to accommodate the washers-.88 and screws 48. The plates 8and 1..are1 secured to frames 82 and 88 respectively. 'I'hefframesfl! and 8,8 extend from end to end of the machine and provide ledges 84 upon which the rear vmarf gins of the blades 8 and 1 may be secured. Clamping bars 88 and 88 are, secured to the frames 82 and 88 by any suitable means such as bolts 81. The clamping bars 88 and 88 secure the rear margins of the blades 8 and 1 to the frames 82 and 88 respectively. At their lateral extremities the frames 82 and 88 are positioned in ways 88 and 88 respectively. The ways 88 and 88 are formed in the lateral extremities of the castings 8 and 8. At their lateral extremities castings 8 and 8 have formed therein ledges 88, see Fig'. 5, and are provided with projections 8l on the top of which are secured gib plates 82. The-spacebetween the gib plates 82, the ledges 88 and the proiections 8I forms the way in which the frames and I9 slide. The gib plates 92 are secured to the projections 9| by screws or in any other suitable manner. Thus, it is seen that the plates or blades 9 and 1 may be moved independently of the brackets 9 and 9 in a direction perpendicular to the direction of movement of the web W. but that the plates or blades 9 and 1 are carried by the castings 9 and 9 in movements parallel to the direction of the motion of the web W. I

The frames 52 and 99 have vertically extending lugs 99 to which are secured blocks 94 and 95 on frames 52 and 53 respectively. The blocks 94 and 95 are provided with wedge slots or ways 99 in which the links 91 and 99 slide, the links 91 and 99 being provided with way followers of a shape corresponding to that of the ways 99. The way followers of the links 91 and 99 fit the ways 99 tightly enough to maintain the links 91 and 99 substantially rigid. The links 91 and 99 are bifurcated at their free extremities as indicated at 99 and a block is pinned between the bifurcations as indicated at 19. The blocks are arranged to slide in rectangular slots 1I formed in radius arms 12. which radius` arms are rigidly fixed upon shafts 13. 'Ihe shafts 19 are mounted for rotation in the brackets 3| and 92 carried by the frame of the machine. 'I'he shafts 13 have rigidly fixed thereon cam levers 14 and 15 corresponding respectively to frames 52 and 53 and blades 9 and 1. The cam levers 14 and 19 carry cam followers 19 which ride in cam slots 11 in cams 19 and 19 respectively. Cams 19 and 19 are rigidly fixed upon the shafts 42 and 4I respectively driven as before described.y The rotation of the cams 19 and 19 effects oscillation of shafts 13 through the cam levers 14V and 15 which in turn oscillate thev radius arms 1 2 thereby effecting reciprocation ofthe frames 52 and 53 through the links 91 and 99. Reciprocation of the frames 52 and 53 carries the blades 9 and 1 in reciprocatlon.

The cam slots in the cams 19 and I9 are so made that one blade is always stationary when the other is moving. The cam slots in all four of the cams 39, 49, 19 and 19 are arranged so that the following cycle of operations takes place. Referring to Figs. 1 to 5, the blade 1 moves to the left to fully extended position, when the blade 1 stops the blade 9 is withdrawn to -the fully withdrawn position, the castings 9 and 9 being stationary at that time. After the blade 9 has reached its fully withdrawn position the blades 9 and 1 both remain stationary relative to the castings 9 and 9, and the castings 9 and 9 move in a direction parallel to'the web, the-casting 9 moving upwardly and the casting 9 moving downwardly until the relative positions of the blades 6 and 1 are reversed. When the castings 8 and 9 have reached the Afull extent of their movement they stop. and the blade 9 moves to the right to its fully extended position, the blade 1 then is withdrawn toits fully withdrawn position and the operation of the blade 1 isfollowed by the movement of the castings 9 and 9 in a reverse direction to that before described until the parts reach their original positions as shown in Figs. 1 and 5.

The-machine isconstructed so. as to` permit of adjustment of the castings 9 and 9 relative to one another so as to adjust the width of the opening I and the machine is also adjustable to provide for increased or decreased lengthof the stroke of the blades 9 and 1 so as to accommodate the stroke of the blades 9 and 'I to the spacing between the castings 9 andl.

As before described the posts I9 and I4 upon which the frames 9 and 9 are reciprocable are carried in castings Ilsecured to the frame I9 of the machine by bolts I9'. The apertures inthe frames I9 through which the bolts I9'.pass are elongated slots so that by loosening the bolts I9' the castings I9 may be moved upon the frame of the machine thereby moving the posts I9 and I4 and carrying the castings 9 and 9 with them so as to adjust the castings 9 and 9 relative to one another. In order to provide for the adjustment of the castings I9 on the frame I5 of the machine, there are provided screws 99 threaded into apertures in the castings I9. Screws 99 are carried rotatably in bearings 9| on the frame of the machine, and upon rotation of the Vscrews 99 the motion of the castings I9 is effected provided the screws I 9' are loose. The screws 99 carry rigidly the worm wheels 92 cooperating with worms 99 carried rigidly upon shafts 94 rotatable in suitable bearings'carried by the frame I5 of the machine. The shafts 94 carry hand wheels 95 by which the operation of the screws 99 may be effected so as to adjust the spacing of the castings 9 and 9. When the castings 9 and 9 are satisfactorily adjusted, the screws I9' are tightened to secure the castings in place.

'Ihe mechanism' for effecting the adjustment of the stroke of the blades 9 and 1 is as follows: as before described the frames 52 and 53 to which the blades 9 and 1 are attached carry the blocks 94 and 95 having vertical Ways .99 in which the links 91 and 99 are fitted for movement. At the top of the blocks 94 and 95 are provided the brackets 99 in which are rotatably supported the screw threaded shafts 91. Shafts 81 carry rigidly bevel gears- 99 with which cooperate the bevel gears 99 secured upon shafts 99. The shafts 99 are rotatable in bearings carried by the brackets 99 and are provided with hand wheels 9I operable to rotate thefsrews 91. The screws 91 are threaded into apertures in the links 91 and 99 so that upon rotation of the screws 91 by manipulating the hand wheels 9| the links 91 and 99 are moved in the ways 99 of the blocks 94 and 95. ways 99 causes a corresponding movement of the blocks carried in the slots 1I of the radius arms 12 thereby shortening or lengthening the effective radius of the arms 12, which causes a corresponding shortening or lengthening of the stroke of the blades 9 and 1.

The next step in the process of this invention involves applying to the faces of the folded'web formedby the loops of the folds an adhesive material which will secure the folds together in fixed relation. The adhesive employed may be and preferably is a water dispersion of rubber such as rubber latex which' may or may not contain vulcanizing ingredients., In lieu thereof rubber cements or rubber dissolved in organic solvents may be employed, or any other suitable adhesive of either animal or vegetable origin which will satisfactorily secure the folds together permanently may be employed.

The step of applying the adhesive to the faces ofthe folded web may be carried out in any suitable manner, a suitable mechanism for efectin that step being disclosed in Figs. 4 and 5.

'I'he folded web as it leaves the channel I9 between the castings 9 and 9 is guided at the lateral edges of the folded web by guides 92 which may take the form of steel bars which are posi- The movement of the links 91 and 99 in the tioned at the ends of the slot or aperture i9 and which support the lateral edges of the folded web as it issues from a folding mechanism.

The guides 92 are provided with top and bottom plates 99 which support the faces of thefolded web as it'issues from the folding machine. The guide 92, 99 is conveniently curved as shown in Figs. 4 and 5 so as to carry the folded web from the folding mechanism to the conveyor 99. As the folded web issues from the guide or chute 92, 93.the conveyor belt 95 advances it to the right as shown in Fig. 4 and carries the upper face of the folded web beneath the adhesive applying machine 99. The adhesive applying machine preferably takes the form of a roller 91 driven conveniently by the chain 99 from the conveyor. The roller 91 passes underneath the vat 99 which rests upon the upper surface of the roller and supplies adhesive thereto. The roller 91 may have indentations ,iin the surface in order better to carry the adhesive. The adhesive may be supplied to the vat 99 through a pipe connection |00 as may be convenient. 'I'he adhesive applying Cil mechanism is carried by the frame |0| and is ad- Justable thereon by the bar `|02 supporting the roller 91 and vat 99 which bar |02 is pivoted at, |09 in the frame |0i and is adjustable by the screw |09 so as to accommodate the machine to the thickness of the folded web. The conveyor is conveniently provided with the support |05 over which the belt 95 passes. As the folded web with the adhesive applied to the upper surface thereof is carried on by the conveyor belt 95, it passes beneath the heating coils |09 or any other suitable form of heating apparatus so as to set the adhesive.

The amount of heat supplied by the heating unit |09 is determined by the nature of the adhesive material, whether it is onewhich merely requires drying or one which requires drying and curing or vulcanization as well. The finished product may be one in which the pile is supported or fixed in place solely by the adhesive material which forms, as well. the backing. If that type of product is desired, the next step in the proc'ess consists in applying the adhesive to the other face of the folded web. to the other face of the folded web according to the machine in Fig. 4 the web is carried over the roller |01 and passed on to the conveyor |09. As

lwill be evident from the operation of the machine in Fig. 4 the uncoated face of the folded web will be uppermost when it reaches the conveyor |09. The conveyor |09 carries the web beneath the cement applying machine |09 similar in all respects to that shown at 99 in Fig. 6 where adhesive is applied to the uncoated face of the web. The web is then conveyed beneath the heating unit ||0 which sets the adhesive.

At this stage in the proc'ess the article consists of the folded web having adhesive on both faces thereof. In order to produce pile fabric from such an article it is next cut along a plane intermediate the faces to which the adhesive is applied. Such a cutting operation may be effected as shown in Fig. 'l by feeding the folded web through rollers between supporting bars ||2, and to the continuously operating knife ||9 of a conventional type, which serves continuously to cut the folded web along a plane intermediate the facesof -the folded web so asv to form the sheets of pile fabric ||9.

Where the nnished article is to have a backing, it is convenient to apply that backing immediately after the cement is applied to each .of the To apply the adhesive faces, although the backing may be applied after adhesive has been applied to both faces of the folded web. or if desired the adhesive by which the backing is stuck to the face of the web may be employed for securing the folds of the web together.

Apparatus for applying the backing is shown in Fig. 4 where the backing lil is drawn from supply roller ||9 and passed beneath the doctor blade ||1 where adhesive |i9 is spread upon the face of the backing. As the backing leaves the doctor knife ||1 it passes around roller ||9 and is brought into contact with the face of the folded fabric as it is moved along conveyor 95. The roller |20 is provided for pressing the backing into intimate contact with the face of the folded web. Where the backing is applied as shown in Fig. 4. the adhesive may be applied by the machine 99 or not as desired. If the adhesive is not applied to the face of the folded web a sufilcient amount of adhesivel must be supplied to the backing ||9 to adequately secure the folded web to the backing as well as to adequately fix the folds in the web. As the foldedweb with 'the backing ||5 applied thereto advances it passes on to the conveyor |09. If desired adhesive may be. applied to the other face of the web by the machine indicated at |09. Whether or not adhesive be applied by the machine |09 to the other face of the web, a backing is applied to the web |2| from the roller |22, doctor knife |29 being provided for applying adhesive |29 to the backing, which backing is rolled on to the face of the web by the roller |25. Roller |29 is provided for rolling the backing and face of the web intq intimate contact. The web with the two backings applied thereto is then conducted away by suitable conveyors |21 and it may be passed through any suitable heating unit to set the adhesive applied to the backing and to vulcanize the adhesive if it be of a vulcanizable nature.

The adhesive material found most satisfactory for securing the folds of the web together and also for securing the backing tothe web has been found to be a latex compounded with vulcanizing ingredients. v

' The folded web with the backings |I9 and |2| is finally fed to the cutting machine shown in Fig. 7 which divides the folded web between the faces thereof so as to form a pile fabric.

While the preferred method and mechanism for applying adhesive and backings to the folded web is illustrated in Figs. 4 and 6, other methods and mechanisms may be employed for accomplishing the same result. For instance the process may be modified so as to apply the adhesive to both faces of the folded web simultaneously and to apply backlngs to both faces of the folded web simultaneously. Mechanism for carrying out such a process is illustrated in Fig. 13. As shown in that figure the folded mechanism is of a construction like that hereinbefore described. As the folded web passes from the folding mechanism, travelling belts |29 passing over pulleys |29 driven from any suitable source of power are provided for advancing the folded web. By controlling the speed of the belts |29 the spacing between the folds of the web may be controlled. If the belts travel at faster speed than the folded web is supplied from'the folding mechanism. the folds will be opened to a degree proportionate to the difference in speeds. Ii' necessary the belts |29 may be driven at a slower rate ot speed than the web normally advances from the folding mechanism thereby. causing the folds to be more tightly compacted. The adhesive may be applied to the folded web either before or after passing through the belts |23 and preferably after passing therethrough as shown in Fig. 13 in which case vthe folded web between 'supporting plates |30 which extend across the entire faces of the folded web and lend support thereto to maintain it infolded condition. The plates |33 are provided with apertures |3| which conveniently may be arranged diagonally so that no fold is left unsupported across the entire face of the web. In lieu of the blades I3! a coarse wire mesh may be employed which will lend satisfactory support to the web and also permit .the passage of the adhesive therethrough. The adhesive is applied to both faces of the folded web simultaneously' from sprayingr units |33 of any conventional construction. As before. the adhesive may be of any nature suitable to the purpose for which it is employed, that is, either rubber latex, rubber cement, or animal or vegetable adhesive. If the inall product is not to have a backing other than the adhesive, the folded web with the adhesive thereon is next passed through the heater |33. The heater is provided with the channel |34 to accommodate the passage of the folded web and with steam coils |35 arranged in chambers |38 so as to supplyheat in the desired quantity and at the desired temperature for setting or vulcanizing the adhesive.

If the inal product is to be provided with backings B, it is convenient to apply such backings immediately after the folded web issues from the adhesive applying mechanism. As shownin Fig. 13 the backing may be brought from any suitable source of power beneath doctor blades |31 which apply adhesive |38 to the surface of the backing, the backing being supported by the table |39. The backing is drawn from the table by the rollers and the motion of the advancing web. 'I'he backing B passes over the rollers |40 which press it into contact with the faces of the folded web. The folded web with the backing applied to the faces thereof then passes through the heating |33 for setting or vulcanizing the adhesive as this mixture may require. As the folded web with adhesive and/or f backing applied thereto issues from the heated unit |33 it is conveniently divided along a plane lbetween its faces by the cutter unit l4| of conventional. construction.

'I'he product without backing other than adhesive which is applied to hold the folds together takes the form shown in Fig. 8 before cutting the .folded web between its faces. After cutting the product takes the form shown in Fig. 11 in which the pile consists of the upstanding ilbres F secured together by the backing A. The vnature of the product is determined by the kind of bres employed and the depth of the pile. It is clear from the process herein described and the mechanism for carrying that process into effect thatarcanos article lends itself readily t0 ses Buch .s ull-- thereof, produces the product shown in Fig. 10 v which is composed of the pile F, the adhesive R. for holding the pile together and the backing B which lends strength and durability to the product. The backing B may be oi' any suitable material such as an inexpensive woven fabric or wire cloth or paper or any other suitable material of suilicient strength whichmay be satisfactorily unitedy to the pile by adhesives.

Where it is desired, pile fabrics of various colored designs may be made up by cutting out sections of various shapes such as shown in Fig. 12 where two pieces of rectangular shape P and Q are juxtaposed and united upon a common backing. Separation may be done by hand or machine and the contour of the parts P and Q and the color of the materials from which they are made may be of whatever is desired. The pile of the fabric may be made in a large variety of colors by vemploying strands of variously colored fibrous material or by employing strands which are variously colored throughout the length, or

the ilnished product itself may be printed upon so as to form asuperficial coloring thereon. Or if desired designs may be printed upon the ad- `vancing web prior to folding, the designs being printed in a shape such that when folded the final design will be that desired, in which case the color of the design will extend to the full depth of the pile.

While certain methods, devices and products have been described by way of illustration of this invention, it is not intended so to limit the inven-` tion inasmuch as it may be varied in many of the details ofthe process and apparatus and the vproduct may be varied within wide limits as to width, depth of pile, coloring effects, the nature of bre employed, the nature of the backing material, the -nature of the adhesive, and the order in which they are assembled in nnal relation.

Foran understanding of the scope of the invention, reference is made to the following claims. Having thus described my invention, what I yclaim and desire to protect by Letters Patent is:

` 1. A machine for manufacturing fibrous sheet material comprising in combination, apparatus* for continuously-advancing ilbrous material in web form, parallel blades arranged transversely of and edgewise to the web, means for reciprocating the blades to fold the web, members against which the web is clamped by the blades, mechanism for reciprocating the blades in a direction parallel to the web, the means and mechanism being so synchronized that the motion of the blades parallel to theweb takes place only when one blade is fully extended and the other fully withdrawn.

2. A machine for manufacturing nbrous sheet material comprising in combination apparatus for continuously Yadvancing brous material in web form, parallel blades arranged transversely of and edgewise to the web, means for reciprocating the blades to fold the web, members against which the web is clamped by the blades,

mechanism for reciprocating the blades in a direction parallel to the web, the means and mechanism being so synchronized that the motion of the blades parallel to the web takes place only when one blade is fully extended and the other fully withdrawn, and means for adhesively securing the loops of the folds.

3. A mlachine for manufacturing fibrous sheet material comprising in combination Y apparatus for continuously advancing fibrous material in web form, parallel blades arranged transversely of and edgewise to the web, means for reciprocating the blades to fold the web, members against which the web is clamped by the blades, mechanism for reciprocating the blades in a direction parallel to the web, the means and mechanism being so synchronized that the motion of the blades parallel to the web takes place only when one blade is fully extended and the other fully withdrawn, means for applying adhesive to the loops ofthe folds, and means for applying a backing to the surfaces formed by the loops of the fold. i

4. A machine for manufacturing brous sheet material comprising in combination apparatus for continuously advancing fibrous material in web form, parallel blades arranged transversely of and edgewise tothe web, means for reciprocating the blades to fold the web, members against which the web is clamped by the blades, mechanism for reciprocating the blades in a direction parallel to the web, the means and mechanism being so synchronized that the motion of the blades parallel to the web takes place only when one blade is fully extended and the other fully withdrawn, means for applying adhesive to the loops of the folds, means for applying a backing to the surfaces formed by` the loops of the fold, and means for dividing the sheets intermediate of the loops.

5. A machine for manufacturing brous sheet material comprising means for supplying brous material in web form, means for repeatedly folding and compacting the fibrous material to form a series of wholly contacting folds with the bends of the folds in two substantially parallel planes, means for adhesively securing the bends of the folds in at least one of said planes, and means for severing the folds between the bends thereof,

6. A machine for manufacturing brous sheet material comprising means for continuously sup- Aplying fibrous material in web form, means for successively forming wholly contacting folds in the fibrous material, the bends of the folds forming substantially parallel faces of the folded web,

throughout its length and having the bends oi!l the folds intwo substantially parallel planes. means for adhesively securing the bends of the folds in the two planes, and means for severing.

the folds between the said planes.

8. A machine for manufacturing fibrous sheet material comprising means for supplying brous material in web form, means for successivelyI forming folds in the fibrous material having each side of a fold contacting a side of an adjacentv fold throughout its length, the bends of the folds forming substantially parallel faces of the folded web, means for adhesively securing the bends of the folds in the ytwo faces, and means for severingthe folds between said faces.

9. A machine for manufacturing fibrous sheet material comprising means for supplying fibrous material in web form, meansfor successively forming contacting folds in the brous material, the bends of the folds forming substantially parallel faces of the folded web, means for adhesively securing the folds in said faces and means for dividing the sheet along a plane parallel to the faces of the material and intermediate thereof.

10. A machine for manufacturing fibrous sheet material comprising means for continuously advancing fibrous material in web form, reciprocating means for repeatedly and successively forming folds throughout the width of the advancing web, the bends of the folds forming substantially parallel faces of'the folded web, means for adhesively securing. the folds in said faces, and

ERNEST HOPKINBON. 

